1.

What is defined as "the supervision of a process designed to alter and improve the
function of a business"?

 Change Management.(Correct)
 Incremental Management
 Strategic Planning.
 Commitment Management.

Explanation
Supervision often includes conducting basic management skills (decision making, problem
solving, planning, delegation and meeting management), organizing teams, noticing the need for
and designing new job roles in the group, hiring new employees, training new employees,
employee performance management

2.The primary purpose of operation’s involvement in the maintenance program is to:

 Increase the skill levels of operations.

 Reduce maintenance workforce staffing and maintenance costs.
 Increase stakeholder contributions to asset maintenance (Correct)
 Improve plant (facility) housekeeping and decrease contractors.

Explanation
The maintenance function is responsible for the frequency and level of maintenance. They are
responsible for the costs to maintain, which requires development of detailed budgets and control
of costs to these budgets. This is an essential element for the successful operation of a
maintenance management system. So stakeholders contribution is very crucial.

3.The best way to achieve employee buy-in acceptance of the Maintenance and Reliability
Program is to:

 Sub-contract all maintenance work and have existing employees becomes inspectors.
 Develop a pay structure that rewards reactive maintenance performance.
 Begin a campaign to recruit volunteers to participate in the Maintenance and
Reliability program
 Link employee to his job, link the job to the process, and link the process to the
organizational goals.(Correct)

Explanation
Goal-setting is particularly important as a mechanism for providing ongoing and year-end
feedback. By establishing and monitoring targets, you can give your employees real-time input
on their performance while motivating them to achieve more.
4. Arrange the following cascading indicators in descending order: 1)Schedule compliance
2)Return on Invested Capital 3)Uptime 4)Equipment reliability 5)Plant (Facility)
Profitability 6)Production volumes

 2, 1, 3, 4, 6, 5
 2, 5, 6, 3, 4, 1(Correct)
 2, 5, 6, 4, 3, 1
 3, 5, 6, 4, 1, 2

5. Business excellence requires that in most companies the following things must be done
well and effectively integrated:

 Reliability improvement, sales and installation

 Budgeting, executing and follow up
 Marketing, manufacturing, research and development (Correct)
 Communication and recruitment

Explanation
Business excellence in most companies requires that the company do each of three things shown
in Figure 1-1 exceptionally well-marketing, R&D, and manufacturing. Excellence in each is
essential for long-term success, and each must be fully integrated with the other.

6. To be trusted by all members of a group a facilitator must:

 Be acceptable to most of the group

 Have decision making authority
 Be a member to the group
 Not prefer any potential solution (Correct)

Explanation
Be honest: Effective facilitation requires that he facilitator be honest with him/herself and with
the group. This includes being honest about the limits of one's own abilities and knowledge. If
the facilitator doesn't know the answer to the group's questions, s/he should admit it and work on
finding the answer. Always open for new solutions.

7. The practices of a company for which it is accountable in relation to other parties is

called:

 social responsibility(Correct)
 culture
 values
 code of ethics

Explanation
Corporate social responsibility (CSR) is a self-regulating business model that helps a company
be socially accountable—to itself, its stakeholders, and the public. By practicing corporate social
responsibility, also called corporate citizenship, companies can be conscious of the kind of
impact they are having on all aspects of society, including economic, social, and environmental.

8. What would dictate the basic skills requirements for maintenance and reliability
employees?

 The educational demographics of the region

 Skills available in the general work force
 The content of the apprenticeship program
 The current level of plant technology(Correct)

Explanation
Organizations need to have or prepare their workforce who are familiar with M&R best practices
and can be instrumental in creating a sustainable reliability culture.

9. For a reliability Engineer, identify the appropriate KPI below that he /she would be
responsible for:

 Mean time between failures(Correct)

 Equipment utilization rate
 % rework
 Shift stream factor and production rate

10. Workplace health and safety legislation imposes a duty of care on;

 the employee
 the employer
 all participants in the workplace (Correct)
 visitors to the workplace

Explanation
Workplace health and safety legislation imposes the duty of care on everyone at the workplace.

11. Which of the following methods best identifies maintenance problems caused by
maintenance and/or operating processes?

 Root cause Analysis (Correct)

 Pareto Analysis
 Weibull Analysis
 Bottleneck Analysis

Explanation
Root cause analysis is a maintenance troubleshooting method that helps organizations identify
and control the systemic causes of a maintenance problem. When you experience a problem, you
have to start by asking why the problem occurred. You repeat this process until you uncover the
underlying cause.
12. Which of the following can be improved by preventive maintenance?

 Plant Reliability (Correct)

 Time to repair
 Inherent reliability
 Effect of failure

13. The common root cause of bearing failure on hydraulic systems can be attributed to all
the following except:

 Particle contamination during periodic maintenance

 Misalignment during installation
 Water contamination of hydraulic oil
 Wrong bearing design for the application (Correct)

Explanation
The actual root causes of the bearing failure may be that it lacked the correct lubricant viscosity,
proper delivery method, or intervals for the application. They are: fatigue, handling/installation,
operational, environmental, lubrication and defect. Standard wear and tear is one of the leading
causes of bearing failure. Eventually all bearings fail due to wear, however, excessive load,
vibration or force can cause a bearing to wear out long before it should. Most of this excess force
is caused by improper installation.

14. A large manufacturing company installed some asset monitoring device on some large
motors that were deemed critical equipment. The monitoring devices provide engineering
with vibration data, acoustic data, as well as operational performance data. What asset
management strategy has the company selected for the motors?

 OBM (Operational Based Maintenance/CM (Corrective Maintenance)

 PM (Preventive Maintenance/OBM Operator Based Maintenance)
 CBM (Conditioned Based Maintenance)/PDM (Predictive Maintenance) (Correct)
 CBM (Condition Based Maintenance/CM (Corrective Maintenance)

15.What is the relationship between leading indicator metrics and lagging indicator metrics
in the field of Maintenance and Reliability?

 Lagging indicators are measures that reflect accomplishment of goals, while leading
indicators are measures of what must be done to improve results.(Correct)
 Leading indicators are measures that reflect accomplishment of goals while lagging
indicators are measures of what must be done to improve results.
 Leading indicators are low level measures that reflect accomplishment of goals,
while lagging indicators are measures of what must be done to improve results.
 Leading indicators are used by management, while lagging indicators are used by
personnel on the shop floor.
Explanation
A leading indicator informs business leaders of how to produce desired results, a lagging
indicator measures current production and performance. While a leading indicator is dynamic but
difficult to measure, a lagging indicator is easy to measure but hard to change.

16. Grouping of data into families and eliminating statistical outliers from a statistical
alarm calculation:

 Will only affect the bad data but not affect the good data.
 Can be dealt with by using the percent offset method.
 Must be performed to assure reliable predictive maintenance intervals.(Correct)
 Is not necessary as the standard deviation process corrects for all deviation.

17. Which of the following option identifies the primary purpose for statistical process
control charts in manufacturing?

 To determine statistical distribution for a process or product

 To monitor manufacturing team performance
 To supply quality data to a customer
 To monitor process or product variation.(Correct)

Explanation
The aim of Statistical Process Control (SPC) is to establish a controlled manufacturing process
by the use of statistical techniques to reduce process variation. A decrease in variation will lead
to: better quality; lower costs (waste, scrap, rework, claims, etc.).

18. Which of the following options least likely to be linked to maintenance and the
reliability process improvements?

 Reduced work
 Lowering operating costs
 Improved product design (Correct)
 Better availability/capability

19. For a very stable and capable manufacturing process that is centered on the product
specification, extremely low levels of defects may be identified if the appropriate method is
used. Which choice below specifies the appropriate method?

 Use of process visual inspections.

 Use of process automated inspections.
 Use of process stability charts.
 Use of process control charts.(Correct)
Explanation
The control chart is a graph used to study how a process changes over time. Data are plotted in
time order. A control chart always has a central line for the average, an upper line for the upper
control limit, and a lower line for the lower control limit. These lines are determined from
historical data.

20. Failure modes and effects analyses (FMEA) and root cause failure analyses (RCFA)
have many commonalities. With this information in mind, which one of the following
options presents a statement that would be considered false?

 Both FMEA and RCFA attempt to determine the ways in which equipment may
fail.(Correct)
 FMEA has no value in conducting RCFA.
 FMEA is broader in scope than RCFA.
 FMEA is normally conducted prior to a failure; RCFA is conducted after a failure.

Explanation
Failure Mode and Effects Analysis (FMEA) is a methodology aimed at anticipating equipment
failure by proactively identifying all potential failure modes of the various parts of a system. It
identifies the effects the failures can have on the system and provides a maintenance strategy to
avoid the failure and/or mitigate the effects of the failure on the system. Conversely, Root Cause
Failure Analysis (RCFA) is the process for pinpointing the root cause(s) of a specific failure to
determine what corrective action(s) must be implemented to alleviate or reduce the probability
that the problem will recur due to the same root cause(s).

21. Which selection below indicates the best method used for identifying maintenance
problems caused by maintenance or operating work processes?

 Root Cause Failure Analysis (Correct)

 Bottleneck Analysis
 Weibull Analysis
 Pareto Analysis

Explanation
A root cause failure analysis identifies the underlying issues behind a production problem. It
applies the adage “treat the cause, not the symptom” to manufacturing, where a symptom or
unrelated problem is too often treated because it is the easiest one to identify and address.

22. Which of the following is a valuable health and safety metric that is often overlooked?

 The number of reported accidents resulting in no injury.(Correct)

 The number of reported accidents resulting in lost time.
 The number of reported accidents resulting in first aid treatment.
 The number of reported accidents resulting in no regulatory recordable injury.
23.The 'Karl Fischer Method' measures:

 The count in parts per million (ppm), of coliform bacteria in a sample of cooling
tower water.
 The viscosity of an oil sample based on its flow rate through a calibrated orifice.
 The conductivity in micro-ohms, of a sample of cooling tower water
 The amount of water in a sample of oil, in ppm(Correct)

Explanation
Karl Fischer titration is a classic titration method in chemical analysis that uses coulometric or
volumetric titration to determine trace amounts of water in a sample. It was invented in 1935 by
the German chemist Karl Fischer.
.
24.Reliability predictions are often expressed in terms of Mean Time Between Failures
(MTBF) or its reciprocal the reciprocal is known as the:

 Failure Rate(Correct)
 Failure Mode
 Mean Time to Failure
 Service Life

Explanation
Failure Rate = 1/MTBF

25. Which of the following options states why a majority of preventive and predictive
maintenance programs are not successful?

 There is no reaction to the data.(Correct)

 It takes too long to see results.
 There is lack of management support.
 There is too much management involvement.

26.Which of the following options identifies the measured units used for a mechanical
ultrasound?

 Hz
 KHz
 MHz

(Correct)

 VAC

Explanation
Ultrasonic testing is a type of nondestructive testing commonly used to find flaws in materials
and to measure the thickness of objects. Frequencies of 2 to 10 MHz are common, but for special
purposes other frequencies are used. Inspection may be manual or automated and is an essential
part of modern manufacturing processes. Most metals can be inspected as well as plastics and
aerospace composites.

27.The decision is made to accompany the vibration technician on a data collection route.
Which option below indicates what you should be watching for in the technician
performance?

 The technician should be observing and noting other conditions such as leaks, loose
bolts, dirty oil, failed gauges and the like.(Correct)
 The technician should be collecting measurements in proper route sequence,
allowing for machines that are shut down or not warmed up.
 The technician should be recording measurements from all operating equipment on
the route, regardless of sequence.
 That the technician is taking measurements in displacement and velocity as well as
acceleration units.

Explanation
Every conditions need to be observe carefully so that maintenance can be done in right time
brfore loss of functionality of equipments.

28.Which of the following options states the philosophy of predictive maintenance (PdM)?

 PdM strives to return equipment health to normal before complete loss of function.
 PdM strives to return equipment health to normal after complete loss of function.
 PdM strives to predict future equipment status based on maintenance
experience.(Correct)
 PdM strives to watch for equipment deficiencies when it is convenient.

Explanation
Predictive Maintenance (PdM) is a form of maintenance that tracks and monitors the condition
and performance of equipment during normal operation. By doing so, maintenance managers and
technicians are able to identify possible defects and fix them.Reduce unplanned downtime of
equipment that is critical for production.

29. The historical evolution of maintenance methods from earliest to latest has been:

 Breakdown (reactive), predictive, preventive, reliability centered.

 Reliability centered, predictive, preventive, breakdown (reactive).
 Breakdown (reactive), preventive, predictive, reliability centered.(Correct)
 Preventive, reliability centered, predictive, breakdown (reactive).
30. Which of the following has the least impact on maintenance and operation process
improvements?

 Preventive maintenance
 Age and condition of assets(Correct)
 Cross functional improvement teams
 Manufacturing teams

Explanation
Age and condition of assets doesn’t matter as long as the function of the asset is proper and
having desirable outcome.

31.Considering the task numerically listed below, which of the following answers includes
the tasks that should be used to incorporate changes to process and equipment? 1-Use an
accepted risk analysis process when a change is made. 2-Use a database to record
equipment failures. 3-Use change procedures and policies to document changes. 4-Use cross
functional teams to conduct safety, operability, and maintainability reviews.

 1,2,3
 1,2,4
 1,3,4(Correct)
 2,3,4

32. Which of the following option names a failure that, when avoided, is considered a “best
practice” for industrial maintenance?

 Manufacturer – induced Failure

 Design –Induced Failure
 Machine-Induced Failure
 Self-Induced Failure(Correct)

33 .As a reliability engineer, which option below lists the key performance indicator(s) for
which you would be accountable?

 Mean Time Between Failure(Correct)

 Percentage of Rework
 Shift Stream Factor and Production Rate
 Equipment Utilization Rate

Explanation
Mean time between failures (MTBF) is the predicted elapsed time between inherent failures of a
mechanical or electronic system, during normal system operation. MTBF can be calculated as
the arithmetic mean (average) time between failures of a system.
34.After repeated re-organization of the Maintenance and Reliability structure, only
marginally better performance was realized. To get improved results from your team you
should first:

 Assess what gaps exists in processes and people.(Correct)

 Develop and communicate a new strategic plan.
 Develop better training materials.
 Establish key performance indicators.

Explanation
A gap analysis is process that compares actual performance or results with what was expected or
desired.By comparing the current state with the target state, companies, business units, or teams
can determine what they need to work on to make their performance or results better and get on
the right path quicker.

35. Which option below names the first step in employee progressive disciplinary process?

 Written warning
 Coaching or counseling(Correct)
 Verbal warning
 Suspension

Explanation
A verbal counseling is generally the first step of progressive discipline. A verbal counseling is
intended to be used by a manager/supervisor to notify an employee that an improvement is
needed in the employee's work performance and/or behavior.

36. Which of the following is the best definition of a work-team?

 Supervision defines mission, direction and assesses performance. The team is largely
self-governing and is responsible for accomplishing goals.(Correct)
 The team defines mission and direction. Supervision and the team are responsible
for accomplishing the goals.
 Supervision provides all work direction and holds the team accountable for results
 The team defines direction and conducts poor performance assessments

37. Which of the following answers best describes the characteristics of a good key
Performance Indicator for maintenance processes?

 Encourages the right behavior, difficult to manipulate, easy to measure(Correct)

 Causes the employees to feel good about themselves and their work
 Focuses on indicators that require interpretation and analysis by multiple
departments
 Provides a single indicator as to how maintenance performance directly affects the
company bottom line
38.Which of the following options specifies an element that is not part of a well-developed
Training Strategy?

 Definition of skills requirements

 Gap closure plan
 Assessment of current skills
 Performance reviews (Correct)

Explanation
Performance reviews are not part of training program.

39. Which of the following options designated the most effective method of performance
evaluation?

 A field review process

 An employee written assessment
 A feedback process
 A behaviorally anchored rating scale process (Correct)

Explanation
Behaviorally anchored rating scale (BARS) is designed to bring the benefits of both qualitative
and quantitative data to the employee appraisal process by comparing an individual's
performance against specific examples of behaviour which are then categorized and appointed a
numerical value used as the basis for rating performance.

40. Which option below identifies the analysis process that can best be used to perform a
gap analysis?

 Benchmarking (Correct)
 Risk analysis
 Root Cause Analysis (RCA)
 Fishbone diagram

Explanation
Benchmarking is the process of comparing the current project, methods, or processes with the
best practices and using this information to drive improvement. The Gap Analysis naturally
flows from the Benchmarking Analysis.

41. One way to stimulate and motivate a team member is to understand what desires drive
human behavior in a work environment. Which option below names a desire that does not
motivate team members most of the time?

 Desire for recognition

 Desire for a paycheck (Correct)
 Desire for competence
 Desire for ownership
42. Considering the four tools and techniques listed below, which of the following option
identifies those that are seen as the leading tools techniques used to identify maintenance
and reliability process improvements? 1-Total Productive Maintenance (TPM) 2-
Reliability Centered Maintenance (RCM) 3-Historical analysis of spending patterns 4-
Process benchmarking with industry leaders

 1,2,3
 1,2,4 (Correct)
 1,3,4
 2,3,4

43. Which of the following is the true phrase?

 Availability is the probability that an item can perform its intended function for
specified interval under stated conditions.
 Equipment availability is calculated by dividing performance rate into total hours
available to run.
 If equipment has low availability then, automatically, it has low reliability.
 Availability measures the percent of time that the equipment can be used (24-7-365),
divided into the equipment uptime (actual production).

Explanation
The measurement of Availability is driven by time loss whereas the measurement of Reliability
is driven by the frequency and impact of failures. Mathematically, the Availability of a system
can be treated as a function of its Reliability. In other words, Reliability can be considered a
subset of Availability.

45. What should be done first to address a gap between your manufacturing performance
and World Class performance?

 Develop gap closure plans and begin to implement them

 Assign additional resources to work on attaining World Class performance
 Define the value of the gap to determine its worth to the company
 Review gap analysis to ensure it reflects your current performance
accurately(Correct)

Explanation
Review -> Define -> Develop -> Assign

46. The Maintenance Planner is_______, future oriented, and responsible.

 Reactive
 Tactical
 Flexible
 Proactive (Correct)
Explanation
A maintenance planner is responsible for making sure maintenance technicians have the tools
and parts they need to complete work orders. If there is not a separate maintenance scheduler,
maintenance planners are also expected to schedule maintenance in a way that minimizes
equipment downtime and impact on production.
46. The scheduler owns the schedule, runs the scheduling meeting, and _________.

 Approves all schedule changes

 Is responsible for compliance
 Validates break-ins
 All of the above(Correct)

Explanation
A Maintenance Scheduler is responsible to take a maintenance plan and bring together all the
resources needed to complete it. The Scheduling role involves assembling and coordinating the
information, people, materials, equipment, along with all the other necessary resources to get the
job done.

47.What should Planners focus their efforts on?

 Daily activities
 Expediting parts
 Escorting vendors
 Future work (Correct)

Explanation
Planning is concerned with defining goals for a company's future direction and determining the
resources required to achieve those goals. To meet the goals, managers will develop marketing
and operational plans inclusive of key organizational values (vision, mission, culture, etc).

48. When planning a job make sure to consider the scope, visit the location, create start and
finish points, and be sure the ______is correct.

 Computer
 Supervisor
 Priority
 Scope(Correct)

Explanation
Scope planning involves identifying the goals, objectives, tasks, resources, budget, and timeline.
This chapter includes a number of high‐impact tools that can be added to a project manager's PM
Toolbox to assist with the process of scope planning.
49.The identification of work is essential because it allows you to ________ know the
condition of systems, components and structures.

 Proactively(Correct)
 Reactively
 By Chance
 Passively

50. Why is a Planning Checklist Important?

 Creates more paperwork

 Another use for the Computer
 Let’s the Boss see if I’m doing my job
 Provides a consistent process for planning (Correct)

Explanation
The planning checklist is a visual reminder of the “heart” of the detailed planning process. The 5
main steps in the checklist are: Safety. Job steps, timing of each step, and overall time.

51. Long Range planning is important because it helps us remember needed activities,
avoid deferments, and prevent scheduling conflicts.

 TRUE (Correct)
 False

Explanation
Long-range planning is key to bridging the gap between where your organization is and where
you want it to go. Starting with strategic planning, it's an effective technique for designing and
implementing effective plans to take the organization down the road to the future.

52.The four categories of long-range planning are: known major events, seasonal
constraints, regulatory requirements and________.

 Emergency work
 Backlog
 Preventive maintenance activities (Correct)
 Crafts Schedules

53.We schedule work in advance because we can coordinate activities between

departments, parts and support will be available, and we _________.

 Look good to have lots of scheduled activities

 Can complete more work per unit of time (Correct)
 We no longer have break-in work
 Can better expedite parts
Explanation
It ensures that you complete your responsibilities in the time allotted. Sure. There will be times
when you finish early or have to put in overtime. But, having a consistent work schedule
encourages people to get their work done effectively and efficiently.

54. High schedule compliance is the goal, and the success or failure of a scheduling effort
depends greatly on team work and _______.

 Communications
 Discipline (Correct)
 Management
 Operators

55.Encourage Materials Management representation at weekly planning meetings, provide

feedback on Material quality, and above all try to fix their problems.

 True
 FALSE(Correct)

Explanation
How to plan more effective meetings with a weekly team agenda -Create a weekly team agenda.
-Make it a virtual meeting. -Consider time management in your meeting agenda. -Be committed
to those working remotely. -Rotate who runs the meeting. -Make it an optional meeting for
certain team members.

56. The core values, beliefs, and assumptions that are widely shared by members of an
organization are known as:

 Organizational climate
 Strategic plan
 Mission statement
 Organizational culture (Correct)

Explanation
Organizational culture is defined as the underlying beliefs, assumptions, values and ways of
interacting that contribute to the unique social and psychological environment of an organization.

57. You are a senior reliability consultant at a firm. A graduate student was assigned to
come up with reliability projects that are value add to the organization. Explain what value
add means?

 It is the value that a firm adds through the development of dynamic capabilities
 It is the value that a firm adds to bought-in materials and services through
outsourcing.
 It is the cost saving through production and marketing efforts within the firm
  It is the difference between the cost of inputs and the market value of outputs
(Correct)

Explanation
Value added is the difference between the cost of inputs and the market value of outputs

58. SIPOC is a Six Sigma tool used in the “Define Phase” of the DMAIC process, to gather
information about any process. SIPOC stands for?

 Systems, Inputs, Process, Output and Consumers

 Suppliers, Inputs, Process, Output and Customers (Correct)
 Suppliers, Imports, Process, Output and Consumables
 Suppliers, Imports, Products, Output and Customers

Explanation
SIPOC is a tool that summarizes the inputs and outputs of one or more processes in table form.
It's an acronym that stands for Suppliers, Inputs, Process, Outputs and Customers.

59. Which of these is identified in a company's mission statement?

 Vision
 Financials
 Location
 Purpose(Correct)

Explanation
A mission statement is a short statement of why an organization exists and it defines the purpose
or what its overall goal is, identifying the goal of its operations: what kind of product or service
it provides its primary customers or market, and its geographical region of operation.

60. In terms of goals, what does the acronym SMART stand for?

 Specific, Maintenance oriented, Achievable, Readiness-level, Tactical

 Short, Measurable, Actionable, Results-focused, Tactical
 Specific, Measurable, Achievable, Results-oriented, Time-bound (Correct)
 Specific, Meaningful, Applicable, Realistic, Trademarked

Explanation
SMART is an acronym that stands for Specific, Measurable, Achievable, Realistic or Results-
oriented, and Timely. Therefore, a SMART goal incorporates all of these criteria to help focus
your efforts and increase the chances of achieving that goal

61. A safety management system defines:

 The safety processes and milestones for a development project

 The safety evidence requirements for a system test programme
  A whole organisation’s approach to incident management
 A whole organisation’s approach to workplace health and safety.(Correct)

Explanation
Safety management system (SMS) refers to a systematic approach to managing workplace safety
by organizational goals, policy, structure, planning, accountability and safe standard operating
procedures.

62. What is the first stage of risk assessment?

 Toxicity study

 Risk characterization
 Hazard identification(Correct)
 Exposure assessment

Explanation
Hazard identification is the first stage of risk assessment. It provides a clear understanding of
hazards present at the workplace e.g. chemical contaminants, their concentration and distribution
in the environment.

63. In an automobile manufacturing facility, the management has brought down the cost of
producing automotive components from $500 to $50 through the introduction of new
technology and producing more components per factory. Which of the following concepts is
most likely the results of the cost reduction per component produced?

 Economies of scale (Correct)

 Just-in-Time manufacturing
 Reliability Centered Maintenance philosophy
 5S methodology

Explanation
Economies of scale a proportionate is the saving in costs gained by an increased level of
production per factory.

64. Which of the following best describes Workplace Risk Assessment?

 Risk Assessment is the process of investigating hazards to determine their

likelihood, potential severity, and other factors such as persons at risk.(Correct)
 Risk Assessment is the process of determining whether hazards have been reduced
to ALARP
 Risk Assessment is a process for determining the severity of potential accidents that
might arise from identified hazards
 Risk Assessment is the process of deciding whether a system is acceptably safe
65. The production cost per unit can be reduced by

 Producing more with the same inputs (Correct)

 eliminating idle time
 None of these
 Producing more with an increased input

Explanation
Producing more with the same input is the most probably answer. This encompasses eliminating
waste, improving equipment availability and reliability in addition to improving the overall
equipment utilization.

66. A management concept under which all managers and employees at all stages of
company operations strive toward higher standards and a reduced number of defective
units is called:

 Total Quality Management (TQM) (Correct)

 Theory of Constraints (TOC)
 Total Quality Control (TQC)
 Continuous Improvement

Explanation
Total Quality Management (TQM) requires a focus on quality throughout the production
process. The strategy is to find defective work when and where it occurs.

67. The system reliability of a parallel system:

 Increase if the subsystem with the lowest reliability is removed

 Is equal to the reliability of the ‘best’ subsystem
 Decreases as more redundant subsystems are added to the system
 Is greater than the reliability of any subsystem (Correct)

Explanation
This construction of the parallel system permits the improvement of reliability overall, even
above the reliability of the individual components.

68. Consider a two-component parallel system. If both components are both working, then
the system is working. If either component 1 or component 2 fails, the system is still
working. If and only if both components fail, then the system fails. Unlike a series system
where any one failure causes a system failure, in this simple parallel example, two failure
events have to occur before the system fails.A characteristic of a series system model is

 simplest of any system model

 All of these (Correct)
 Lowest reliability of any system model
 Fewest number of components of any system model
69. An approach that aims to identify the product or service feature that is critical to
various types of failure is:

 Critical incident analysis

 Failure mode and effect analysis(Correct)
 Complaint analysis
 Fault tree analysis

Explanation
Failure Modes and Effects Analysis (FMEA) is a systematic, proactive method for evaluating a
process to identify where and how it might fail and to assess the relative impact of different
failures, in order to identify the parts of the process that are most in need of change. FMEA helps
to identify the product or service feature that is critical to various types of failure

70. The number of failures of an engineered component or system over a period of time is
called:

 None of these
 Mean Time Between Failure (MTBF)
 The failure rate(Correct)
 The average failure points

Explanation
The failure rate is the frequency with which an engineered system or component fails, expressed
in failures per unit of time

71. A fault tree analysis (FTA) differs from a failure mode and effects analysis (FMEA) in
that an FTA

 is typically used in conjunction with a cause and effect diagram

 starts by considering system failure effects or top events first (Correct)
 starts by considering individual or combined lower level failures first
 does not take into account human factors such as incorrect operation

Explanation
FTA will identify combinations of conditions and component failures which will lead to a single
defined adverse effect. FMEA, on the other hand, considers all single component failures in turn
and identifies the range of their effects on the system
72.Number of breakdowns divided by available machine hours is

 Effectiveness of maintenance
 Equipment availability
 Frequency of breakdown(Correct)
 Effectiveness of planning
Explanation
Frequency of machine breakdown is the number of breakdowns divided by available machine
hours.

73. The Weibull distribution represents the relationship between:

 Bearing life and reliability(Correct)

 Static and dynamic load capacities of the bearing
 Bearing life and load bearing capacity
 Number of rolling elements and load capacity

Explanation
The Weibull distribution is widely used in reliability and life data analysis due to its versatility.
The L10 or B10 refers to the life at which 10% will fail (90% will survive) under a given load
can be estimated using Weibull distribution.

74. Which one of the following is not a major test method for a membrane filter?

 Pressure Hold Test

 Pressure Leak Test (Correct)
 Forward Flow Test
 Bubble Point Test

Explanation
There are 3 major tests used to determine the integrity of a membrane filter: The Bubble Point
Test, the Forward Flow, or Diffusion Test, and the Pressure Hold Test. All three tests are based
on the same physics, the flow of a gas through a liquid-wetted membrane under applied gas
pressures.

75. What is the meaning of FTA during equipment reliability analysis?

 Failure Tree Automation

 Fourier Transform Analysis
 Failure Troubleshooting of Assets
 Fault Tree Analysis (Correct)

Explanation
Fault tree analysis (FTA) is a top-down, deductive failure analysis in which an undesired state of
a system is analyzed using Boolean logic to combine a series of lower-level events
76. A manufacturing plant, the maintenance manager wants to ensure that all Safety Data
Sheet (SDS) is updated to the latest versions. All the following information can be found on
the SDS sheet except?

 the health effects of the hazardous substance

 what the hazardous substance should be used for
 the requirement for health surveillance (Correct)
 first aid instructions

Explanation
The requirement for health surveillance is not a piece of information usually found on an SDS
sheet.
77. Which one of the following is the most common qualitative test method for water in the
oil sample?

 Crackle test(Correct)
 ASTM water particulate test
 Vacuum dehydration test
 Gravity separation test

Explanation
One of the easiest ways to measure the presence of free and emulsified water in oil is with the
hot‐plate crackle test. A drop of oil is placed on a hotplate that has been heated to approximately
400° F. The sample then bubbles, spits, crackles or pops when moisture is present.

78. A 20-micron filter will __________________________.

 remove all metallic particles over 20 microns in size

 not work properly if the flow rate is over 20 gpm
 remove all particles over 20 microns in size
 only provide meaningful information if the beta ratio is known(Correct)

79.The weight per unit volume of a liquid at a standard temperature and pressure is called

 Specific mass
 Specific gravity
 Relative density
 Mass density(Correct)

80. What is the beta ratio of a filter media that has a particle size of 50,000ppm at upstream
and 500ppm downstream?

 0.01
 100(Correct)
 99
 5000
Explanation
Beta Ratio refers to the efficiency in which a given filter element removes particles of a given
size. The Beta Ratio is calculated using the ISO multi-pass test standard.The formula for Beta
ration = total particles upstream/ total particle downstream = 50000/500 = 100

81. With series systems, reliability ______________ as the number of components increases

 increases
 is undefined
 decreases (Correct)
 remains constant

Explanation
For a pure series system, the system reliability is equal to the product of the reliabilities of its
constituent components. For example, if you have 2 components with reliability of 90%, the
overall reliability is R=0.9x0.9=0.81 (i.e 81%). Now if we increase the components to 3 with the
same reliability of 90% each, the system reliability becomes R=0.9x0.9x0.9= 0.729 (i.e 72.9%).
There is drop-in system reliability by the addition of the 3rd component.With series systems,
reliability decreases as the number of components increases.

82. A hydraulic pump's primary function is to produce:

 Piston movement in a hydraulic system

 work through hydraulic actuators
 flow in gallons per minute (GPM)(Correct)
 Pressure in pounds per square inch (Psi)

Explanation
A hydraulic pump is a mechanical source of power that converts mechanical power into
hydraulic energy (hydrostatic energy i.e. flows, pressure).It generates flow with enough power to
overcome pressure induced by the load at the pump outlet.The pump does NOT produce pressure
directly, it generates flow measured in GPM or cubic meters per second. The pressure is
produced by restricting the flow.

83. Coefficient of friction is __________________________.

 Ratio of limiting friction and normal reaction(Correct)

 The ratio of force applied to density of material
 The friction force acting when the body is in motion
 The friction force acting when the body is just about to move
84. Name two hydraulic system pressure control valves that typically produce heat in
operation?

 Counterbalance and Unloading

 Sequence and Counterbalance valves
 Relief and Unloading
 Relief and Reducing valves (Correct)

Explanation
There are two pressure control valves: one is a pressure relief valve, and the other is a pressure
reducing valve.Many hydraulic circuits allow the relief valve to dump some or all pump flow to
tank all or part of the time to limit the system pressure to a certain level. When excess pump flow
goes to the tank, it generates heat. The same operating principle applies to pressure reducing
valves.

85. In a highly loaded gear application, which lubrication condition is predominant for
adhesive wear to occur

 Boundary film(Correct)
 Full film
 Elasto-hydrodynamic
 Mixed film

Explanation
Boundary lubrication is defined as a condition of lubrication in which friction between the two
surfaces in relative motion is determined by the properties of the surfaces and by the properties
of the lubricant, other than viscosity.In a highly loaded gear application, the fluid film will be
squished out allowing the gear tooth surfaces to come into metal-metal contact which is
described as boundary lubrication.Boundary lubrication mostly occurs under high-load and low-
speed conditions in bearings, gears, piston rings, pumps, transmissions, etc.

86. When the time period between the testing which detects a failure, for failures with
significant economic consequences, and when life expectancy is highly variable, a good
approach is:

 On-line condition monitoring(Correct)

 More frequent periodic predictive testing
 Structured preventive maintenance
 Time based rebuild or change out
Explanation
When a piece of equipment has an unpredictable life expectancy, no amount of preventive
maintenance or time-based maintenance can prevent failure. The best course of action is to
install instruments (like vibration monitors, oil analysis, flow monitoring sensors etc) to provide
real-time machinery health information for operators and maintenance.

87. A simple computer consists of a processor, a bus and a memory. The computer will
work only if all three are functioning correctly. The probability that the processor is
functioning is 0.99, that the bus is functioning 0.95, and that the memory is functioning is
0.99. What is the reliability of the computer?

 0.9835
 0.9311(Correct)
 0.9767
 0.9001

Explanation
The computer system is considered a series system since all components much work for the
system to work. Component reliability: Process (R1) =0.99 Bus (R2) =0.95 and Memory (R3) =
0.99 Computer reliability (R) = R1 x R2 x R3 = 0.99 x 0.95 x 0.99 = 0.931095

88. What is the formula for Risk Priority Number (RPN?)

 Severity X Occurrence X Detection(Correct)

 Revolutions X Pitch Distance X Number of units
 Risk X Priority X Number of units
 Occurrence X Priority X Index Number

89. The maintenance manager of a manufacturing plant is not happy with his asset
performance. He wants to introduce an asset reliability process to improve the situation.
Which one of these steps must be taken first?

 Align reliability strategy with business goals (Correct)

 Identify which assets contribute to business goals
 Establish asset performance requirements
 Prioritize assets by consequence/relative risk

Explanation
Aligning reliability goals with the business goals is the correct answer because ultimately all the
different departments must align with the corporate goal. If the business goal is to have
equipment running at certain periods of the year for maximum profit, the reliability department
must align and not take the equipment down for maintenance during that peak period. Company
objectives can easily get lost in day-to-day maintenance priorities, so good alignment is key to
corporate success.
90. The maintenance manager of a mining company has all the following as his deliverables
except

 Increasing availability
 Reducing equipment downtime due to parts unavailability
 Increasing MTTR (Correct)
 Increasing MTBF

Explanation
Mean time to repair (MTTR) is a basic measure of the maintainability of repairable items. It
represents the average time required to repair a failed component or device. The maintenance
manager will aim to reduce MTTR.

91. The maintenance cost of a manufacturing plant is considered a ____________________

of performance

 lagging indicator(Correct)
 minor indicator
 true indicator
 leading indicator

Explanation
Maintenance costs are lagging indicators that are the results after the manufacturing process is
complete. They confirm or reinforce established trends.

92. The maintenance manager of a pump company is introducing reliability centered

maintenance. The RCM process received a lot of push back. why do people resist change?

 habit and personal inertia

 fear
 All of these(Correct)
 self-interest

Explanation
In practice, these are the most common reasons why people resist change 1. Loss of status or job
security in the organization 2. Poorly aligned (non-reinforcing) reward systems 3. Surprise and
fear of the unknown 4. Peer pressure 5. Organizational politics 6. Fear of failure 7. self-interest
8. habit and personal inertia etc.
94.Maintenance and reliability organizations conduct employee training on the different
aspects of their business. Normally, the training offered concentrates on:

 coaching the members of an organization how to perform effectively in their current

jobs(Correct)
 none of the above
 expansion of the knowledge and skills of the members of an organization
 Preparing the employees to take on new responsibilities.
Explanation
Training allows employees to acquire new skills, sharpen existing ones, perform better, increase
productivity and be better leaders.Normally, the training offered concentrates on improving
performance in their current job assignment.

94. Which of the following is an objective of Maintenance Management?

 Scheduling
 Maintenance cost control
 All of these(Correct)
 Compliance

Explanation
The most common objectives of maintenance management are as follows: - to optimize the
reliability of equipment and infrastructure; - to ensure that equipment and infrastructure are
always in good condition; - to carry out prompt emergency repair of equipment and
infrastructure so as to secure the best possible availability for production; - to enhance, through
modifications, extensions, or new low-cost items, the productivity of existing equipment or
production capacity; - to ensure the operation of equipment for production and for the
distribution of energy and fluids; - to improve operational safety; - to train personnel in specific
maintenance skills; - to advise on the acquisition, installation and operation of machinery; - to
contribute to finished product quality; - to ensure environmental protection. They achieve these
objectives by influencing scheduling, ensuring compliance, controlling cost, etc.

95. The maintenance manager of a plant has been assigned a task by the board of directors.
He is identified as the final authority and accountable to the given task. He is told that his
role cannot be delegated to any other team member. What is his function in the RASCI
matrix?

 Responsible
 Accountable(Correct)
 Supported
 Consulted

Explanation
In a RASCI matrix, leaders can delegate responsibilities to get the work accomplished. However,
Accountabilities cannot be delegated. The Accountable person is answerable for the correct and
thorough completion of the activity

96. Which portion of a reliability gap analysis allows for the development of strategies to
help implement maintenance and reliability changes?

 Current state
 Future objectives
 Executive summary
 Gap Identification and closure plan (Correct)
Explanation
Conducting a gap analysis can help improve business efficiency, product, and profitability by
allowing the assessor to pinpoint “gaps” present in the company. Once it’s complete, it enables
the business to better focus resources and energy on those identified areas in order to improve
them.

97. Which of the following describes an approach where a company compares its
organizational operations with those of other companies?

 SWOT analysis
 Benchmarking(Correct)
 Competitor performance assessment
 PERT analysis

Explanation
Benchmarking is comparing one’s business processes and performance metrics to industry bests
and best practices from other companies.

98. The advantages of using Six Sigma methodology includes all the following except?

 Leads to trust and higher employee morale within the corporation

 Ensures customer the same results no matter the division in a large corporation
 Ensures that company has more than one manufacturing unit/plant to produce
better quality products(Correct)
 Saves millions without capital investment (making what you have already work
better)

99. Management of a food processing company was tasked to improve the maintenance and
reliability of the company to a world-class standard. The first step in creating a reliability
gap analysis is to:

 Develop strategies for filling the gap

 Analyze financial records
 Look at the current state (Correct)
 Develop future objectives
 Explanation

A gap analysis is an examination and assessment of your current performance for the purpose of
identifying the differences between your current state of business and where you’d like to be.
100. Which of the following is true for inventory control?

 Economic order quantity has minimum total cost per order

 Inventory carrying cost increases with quantity per order
 All of the above(Correct)
 Ordering cost decreases with low size

101. A maintenance activity that is planned and carried out in order to prevent the
occurrence of failure that leads to loss of production is defined as:

 Break-down Maintenance
 Predictive Maintenance
 Pro-active Maintenance
 Preventive Maintenance (Correct)

Explanation
Preventive maintenance is performed while the equipment is operating normally to avoid the
consequences of unexpected breakdowns, such as increased costs or downtime.

102. In developing a RASCI chart using a step by step process, which of the following is
likely the first step of the process?

 Fill out the grid with the letters R(responsible), A (accountable), C (consulted), or I
(informed)
 Identify who will be the project’s participants
 Identifying how each participant involves with each function, decision, task, activity
 Determine the functions, decisions, tasks and activities that will make up the process
or project(Correct)

Explanation
RASCI is a simple tool to manage projects and collaboration, but it’s not a silver bullet. Getting
started using RASCI, one must identify the stakeholders; determine the functions, decisions,
tasks and activities that will make up the process or project.
103. During maintenance planning and scheduling, the planner must consider all the
following except

 The technician skill level required for the task

 Vacation schedule for technicians
 The Production team on the schedule(Correct)
 Impact on production when equipment is taken down

Explanation
The Production team on the schedule is the least important amongst the maintenance planner's
things to consider because it doesn't affect the maintenance schedule as much as Impact on
production when equipment is taken down, Vacation schedule for technicians, the technician
skill level required for the task etc.
104 For a maintenance planning and scheduling, the amount of time it takes to create
purchase requisition, order parts and have it delivered to warehouse ready for use at the
maintenance shop is called:

 Lead time(Correct)
 Vendor management time
 Parts availability
 Mean Time to Delivery

Explanation
Lead time is a crucial part of managing a manufacturing business or any business that involves
waiting for supplies or products to arrive. It is defined as the period of time between the initial
phase of a process and the emergence of results, as between the planning and completed

105. The risk of a breakdown can be greatly reduced by an effective preventive

maintenance program. Nonetheless, occasional breakdowns still occur. Even organizations
with good maintenance practices have to be prepared for breakdowns. Which of the
following provisions are used to deal with breakdowns?

 All of these (Correct)

 Standby or backup equipment that can quickly be put into service
 Inventories of spare parts that can be installed as needed, thereby avoiding lead
times involved in ordering parts, and buffer inventories of work-in-process
 Train operators to be able to deal with emergencies (e.g., know how to lock up
equipment), and perform at least some minor repairs on their equipment

106. The maintenance cost of a manufacturing plant is considered a ____________________

of performance

 minor indicator
 leading indicator
 true indicator
 lagging indicator(Correct)

Explanation

Maintenance cost is a lagging indicator because it is the result after the maintenance process is
complete. It confirms or reinforces established maintenance execution trends.
107. A maintenance technician was called out to perform engine diagnosis on a farm
tractor. After detecting the fault, he ordered a coolant level sensor which took 12hrs to
arrive. The 12hrs in terms MTTR is classified as?

 Labour Delay time

 Slop Time
 Active Maintenance Time
 Parts delay time(Correct)

Explanation
The 12 hrs of waiting for parts will be considered Parts delay time

108. The maintenance engineer of a power plant was attempting to describe the different
types of maintenance to a new hire. In the process, he made a mistake in the classification.
Which of the following is not a classification of maintenance?

 Timely maintenance(Correct)
 Scheduled maintenance
 Preventive maintenance
 Corrective maintenance

Explanation
Five types of maintenance are recurrent in the industry: corrective, preventive, condition-based,
and predictive and predetermined.Timely maintenance is not a recognized maintenance type.

109. The best practice for a scheduler is to optimize operational needs with the availability
and capacity of the maintenance department. Scheduling should ensure:

 A work plan has the right resources assigned to it

 The right tools are available to execute the work
 All materials are on hand to perform the work
 All of the above(Correct)

110. A maintenance technician was asked to perform maintenance on a rotating equipment

at a jobsite 20km from the workshop. In an 8hr day, he spent 2hrs travelling back and
forth to the work location, 2hrs getting tools, parts, work permits and doing Job Hazard
Analysis (JHA). The remainder of his time was used to perform actual maintenance work.
Estimate his wrench time expressed in percentage?

 25%
 50%(Correct)
 75%
 100%

Explanation:Wrench time is the time maintenance personnel spend actually repairing an asset. It
is given by (8-4)/8 x100% =50%